End plate forming apparatus

ABSTRACT

End plate forming apparatus comprising an upper support member and a lower support member provided on the same axis to hold therebetween and revolve a blank and a plurality of sets of forming rollers to be moved on the same locus as the curved surface of the required end plate to form the required end plate by cooperative working.

United States Patent Inventor Yasutoshi Hayashi No. 2, 5-Chome Senbon-don' Nishinari-ku, Osaka, Japan Appl. No. 784,358 Filed Dec. 17, 1968 Patented May 25, 1971 Priority Aug. 24, 1968 Japan 43/60584 END PLATE FORMING APPARATUS 6 Claims, 16 Drawing Figs.

Int. Cl B2lh 1/00 Field of Search 72/80, 81, 82, 83, 84, 85, 86, 87

[56] References Cited UNITED STATES PATENTS 376,167 1/1888 Seymour 72/84 3,145,677 8/1964 Sporck 72/83 3,372,567 3/1968 Jensen, et a1. 72/80 Pnmary Examiner-Lowell A. Larson Attomey-Wenderoth, Lind and Ponack ABSTRACT: End plate forming apparatus comprising an upper support member and a lower support member provided on the same axis to hold therebetween and revolve a blank and a plurality of sets of forming rollers to be moved on the same locus as the curved surface of the required end plate to form the required end plate by cooperative working.

Patented May 25,1971 3,580,025

15 Sheets-Sheet 1 YASUTOSIII n yAsul INVENTOR B1; W/M

ATTORNI'IY Patented May 25, 1971 3,580,025

15 Sheets-Sheet 2 YASU'IOSHI IIAYASIII INVENTOR /wfw ATTORNEY Patented May 25,1971 3,580,025

15 Sheets-Sheet 3 E YASUTOSIII HAYASHI a a INVENTOR BYM EW/M ATTORNEYS Patented May 25, 1971 3,580,025

13 Sheets-Sheet 4 YASUTOSHI HAYASHI INVENTOR [away ATTORNEY Patented May 25', 1971 15. Sheets-Sheet 5 i F a .rw m w I F a A \N A 8 Q4 J B v w m. A) f. VT) #7 C Patented May 25, 1971 15, Sheets-Sheet 6 YASUTOSHI HAYASHI, Inventor LM/iflvM Attorneys Patented May 25,1911 3,580,025

15, Sheets-Sheet 7 YASUTOSHI HAYASHI,

INVENTOR ATTORNEY Patented May, 25, 1971 3,580,025

15 Sheets-Sheet 8 yAsuTosni IIAYASHI INVENTOR ATTORNEY Patented May 25, 1-971 3,580,025

15 Sheets-Sheet 9 Hllllll YASUTOSHI HAYASHI, L mvmon a/MW ATTORNEY Patented May 25,1971 3,580,025

15 Sheets-Sheet 10 I YASUTOSHI uAYAsnJ.

INVENTOR ATTORNEY S Patented May 25, 1971 3,580,025

13 Sheets-Sheet 11 YASUTO3HI HAYASHI INVENTOR .1; (Mad $1.1M

ATTORNEY Patented May 25, 1971 15 Sheets-Sheet 12 YASUTOSHJ'. HAYASI II BYMIZ wM ATTORNEY s a mvsmon Patented May. 25, 1971 3,580,025

15 Sheets-Sheet 15 YASUTOSHI HAYASHI INVENTOR ATTORNEYS END PLATE FORMING APPARATUS This invention relates to an apparatus designed for forming end plates, especially large-sized end plates, for use in boilers, tanks and the like.

In forming end plates, particularly large-sized end plates, it has so far been found most difficult to obtain the desired end plate with the use of a single metal pattern and therefore it has been necessary to prepare many metal patterns and exchange them in regular succession so as to obtain the required end plate.

It is an object of the present invention to provide a novel apparatus whereby a blank supplied is made into'the required end plate automatically by applying to it a series of processes without using a metal pattern, more particularly, an end plate forming apparatus comprising an upper support member and a lower support member provided on the same axis for holding and revolving therebetween an end plate blank and a plurality of sets of forming rollers to be moved on the same locus as the desired curved surface of the end plate to form the required shaped end plate.

The nature and advantages of the present invention will be shown more clearly from the following description made with reference to the accompanying drawings showing the end plate forming apparatus of the present invention, in which:

FIG. 1 is a front view, partially broken away, of the entire apparatus of the present invention,

FIG. 2 is a side elevational view of the structure of FIG. 1,

FIG. 3 is a plan view of the structure of FIG. 1,

FIG. 4 is a detailed drawing of the lower support member,

FIG. 5A is a detailed cross-sectional view of the forming roller,

FIG. 5B is a detailed drawing showing the working condition of the fonning roller,

FIG. 6, FIG. 7 and FIG. 8 show the supporting frame of the forming roller, in which respectively FIG. 6 is a front view of the supporting frame, FIG. 7 is a side elevational view of the structure of FIG. 6, and FIG. 8 is a plan view of the structure of FIG. 6, and

FIG. 9 through FIG. 15 show a modified embodiment, in which respectively FIG. 9 is a side elevational view of the entire structure, FIG. 10 is a plan view of the structure of FIG. 9, FIG. 11 is a detailed cross-sectional view of the fomiing roller, FIG. 12 is a side elevational view of the structure of FIG. 11, FIG. 13 is a cross-sectional view showing the forming roller part and parts related thereto, FIG. 14 is a front elevation showing the detail of the forming roller part illustrated in FIGS. 9 and 10, and FIG. 15 is a side elevational view of the structure of FIG. 14.

In FIG. 1, F denotes a machine frame. Positioned at the top of the frame are rails R, R, on which is mounted an arbor l which is free to travel by means of wheels W, W. Provided on this arbor I is a piston cylinder mechanism 2, comprising a plurality of piston cylinders, which are movable in a vertical direction by means of a pump P. Fixed to the lower part of this piston cylinder mechanism 2 is an upper support member 3 with its under surface or a surface 3a, at which an end plate blank is clamped, made rotatable. Opposite to this upper support member and on the same axis is provided a lower support member 4. Formed in a body at the upper surface of this lower support member is a clamping surface 4a of curved shape to correspond to the inner arcuate surface of an end plate to be formed. Fixed to this lower support member having the clamping surface 4a is a shaft 4b, to a lower end of which is connected a gear 5. As shown by FIG. 4, this gear 5 is provided in a gearbox D below the lower support member 4 and is engaged with a pinion 6 provided around a shaft 6a. A bevel gear 7 carried by the shaft 60 is engaged with another bevel gear 8 provided around an input shaft 9 which is driven by a prime mover or other suitable power source. Under this arrangement, the lower support member 4 is revolved at the required speed by input shaft 9 through the medium of bevel gears 8 and 7, the pinion 6 and the gear 5. At this time, a blank B precut in a discoid form is held between the clamping surface 40 of the lower support member 4 and the surface 3a of the upper support member 3 and revolved with the revolution of the lower support member 4.

Referring now to the structure of the forming roller assembly, a forming roller OR and a press roller 21 are provided within and without, respectively, the outer peripheral edge of blank B. The blank is formed into an end plate of the required arcuate shape as it is held between the two rollers. As shown by FIG. 5A, the forming roller assembly provided with a globe-shaped forming roller OR fixed to a top end of a shaft 10 which is rotatably mounted in a support casing 11 of sheath shape through the medium of bearings 12, 12. Fitted t0 the outer periphery of this support casing through the medium of a bushing 11b is a frame 110. By engaging a pinion 13b provided at a motor fixed to a part of the support casing 11 with a gear 13a fixed to an end portion of a screw'rod 13 provided alongside the support casing 11, the screw rod is caused to rotate by the rotation of the motor 14. By the rotation of this screw rod 13 which is screwed in a part of the frame Ila, the support casing 11 carrying the forming roller OR moves vertically alongside the frame lla. Screwed into a part of this frame 11a is another screw rod 15 supported by a bearing 17. To one end of this screw rod 15 is fixed a gear 15a, with which is engaged a pinion 15b provided at a prime mover 16. By the rotation of the prime mover 16, the forming roller OR and the frame 11a carrying the support casing 11 are moved laterally. By the combination of X, or the range of the lateral motion of the forming roller OR by the prime mover l6, and Y, or the range of the vertical motion of the same by the prime mover 14, the forming roller OR is caused to move on a locus of the required arcuate shape. Such movement of the forming roller is effected by each prime mover on the basis of signals set beforehand, and while the forming roller is moving on the locus of arcuate shape, a rotating blank is formed into an end plate of the required shape. I

Opposite to the forming roller and outward of the blank B is provided a press roller 21 in such a manner that it moves on the same locus as the forming roller. This press roller 21 and the forming roller OR hold therebetween a blank B, which is formed into an end plate of the required shape by the movement of these two rollers.

Referring to the mechanism of the press roller, as shown by FIGS. 6, 7 and 8 a support frame 18 is mounted, slidably in the lateral direction, on a horizontal lower machine frame Fa through the medium of a sliding support member 18a. Provided at this support frame 18 is a sliding frame 19 which slides in the vertical direction. By rotating a screw rod 25 by a motor 26 through the medium of wheels 25b, 25a and chain C, supporting frame 18 is caused to move on the lower machine frame Fa in the lateral direction. The sliding frame 19 is caused to slide vertically by the revolving of screw rods 27a and 27b shown in FIG. 7 which is effected by a motor 30 through the medium of a pinion 29 and a gear 28. In cases where one of the screw rods 27a and 27b has right-handed threads and the other has left-handed threads, they are revolved in an opposite direction from each other so that the sliding frame 19 may slide vertically without trouble. A press roller support frame 20 is slidably provided through the sliding frame 19 through the medium of a bushing 19b. Provided alongside this press roller support frame 20, through the medium of bearings 22a, 22b, is a screw rod 22. Fitted to apart of the screw rod 22 is a part of the sliding frame 19 and fixed to one end of the screw rod 22 is a gear 23a, with which a pinion 23b of a motor 24 is engaged. Under this arrangement, the screw rod 22 isrevolved by the motor 24 through the medium of the pinion 23b and the gear 23a, whereby the press roller support frame 20 is caused to slide laterally against the sliding frame 19. Provided at one end of the press roller support frame 20 is a support frame 21a, within which a press roller 21 is rotatably provided through the medium of a shaft 21b. In this case, the press roller 21 is not supported directly by the shaft 21b but is supported through the medium of the roller frame 21c and accordingly the press roller 21- moves slantingly with the shaft 21b as a center, as shown by the arrow A in FIG. 6.

By means of the combination of the slantwise movement of the press roller 21, reciprocating of the press roller support frame and the vertical motion of the sliding frame 19, these elements move from the position shown by a solid line to the position shown by a chain line in FIG. 6. In cases where an end plate of a smaller diameter is formed by setting the press roller 21 closer to the upper and lower support members 3, 4, the press roller support frame 20 and the support frame 18 carrying the sliding frame 19 should be shifted leftwards as viewed in FIG. 6.

In cases where an end plate to be formed is so large in diameter that it is difficult to manufacture by only a main forming roller OR and a main press roller 21, in cases where an end plate of accurate circularity is manufactured and in some other cases, one or more auxiliary rollers SR should be used. The mechanism of the auxiliary roller is such that as shown at the left of FIG. 1, a support frame 42 provided on the lower machine frame Fa is caused to slide in the lateral direction by revolving a screw rod 44 by a motor 45 through the medium of gears 44a, 44b; a motor 43 provided on a support frame 42 revolves a screw rod 41 through the medium of bevel gears 41b, 41a; a receiving roller support frame 40 carrying a receiving roller 39 is fitted to the screw rod 41 and the receiving roller 39 is moved vertically by the vertical movement of the receiving roller support frame 40. Opposite to the receiving roller 39 is provided an auxiliary forming roller SR, which is fixed to the upper end of a vertical shaft 31 mounted in a support casing 33 of sheath shape through the medium of bearings 32, 32. A frame 33a is fitted to the support casing 33 and a screw rod 37 is screwed into a part of the frame 33a. A motor 38 is connected to a part of the screw rod 37 through the medium of a gear 370 and a pinion 37b, thereby revolving the screw rod 37 and shifting the auxiliary forming roller SR rightward and leftward as shown in FIG. 1.

In forming the required end plate, in order to drive the formingroller OR, the press roller 21, the auxiliary forming roller SR and the receiving roller 39 in such a manner that they move on the predetermined locus, each of the respective driving motors may be set electrically or mechanically and also synchronously or nonsynchronously.

FIG. 9 through FIG. 15 show a different embodiment from the foregoing. In this embodiment, in order to facilitate the sliding of the support casing 11 and the press roller support frame 20, these elements are supported by rollers. Moreover, while the auxiliary forming roller SR is made to move laterally and vertically, the receiving roller is made to move laterally, vertically and arcuately.

FIG. 9 and FIG. 10 show respectively a side elevational view and a plan view of the different embodiment. FIG. 11 shows the modified of the forming roller which is different from the embodiment as shown by FIG. 5, namely, roller receivers 54a, 54a and 56a, 560 are provided above and below the frame 11a, and a pair of large rollers 54, 54 and a pair of small rollers 56, 56 are provided at the roller receivers 54a and 560, respectively, through the medium of the shafts 55, 57. The support casing 11 is caused to advance and retreat, while in contact with the rollers 54, 56, vertically by means of screw rods l3, l3 and motors 14, 14 provided oppositely on either side thereof.

FIG. 13 shows a different embodiment of the mechanism of the auxiliary forming roller, in which an auxiliary forming roller SR is fixed to a shaft 31, which is supported by a support casing 33 through the medium of bearings 32, 32, said support casing 33 carrying a frame 33a through the medium of a bushing 33b being caused to slide vertically through the medium of a motor 36, a shaft 35, bevel gears 35a, 34a and a screw rod 34 and being caused to slide laterally through the medium of a motor 38, pinion 37b, gear 370 and a screw rod 37. A receiving roller 53 opposite to the auxiliary forming roller SR is provided with a frame 46 having a roller support frame 40 with a screw rod 41 passing therethrough. A shaft 47 is supported by the frame 46 through the medium of bearings 47a, 47b in such a manner that it is received by a motor (not shown in the drawings) through the medium of bevel gears 49b, 4911. Fixed to the shaft 47 is a worm gear 48, with which is engaged a worm wheel 50. By the rotation of the worm gear 48, the worm wheel 50 is caused to shift along a guide 46a of arcuate shape provided on the frame 46. The worm wheel carries a support arm 51, at the tip of which is positioned the receiving roller 53 through the medium of a shaft 52. This embodiment aims at correctly effecting the forming of curved edge portion of end plate.

FIG. 14 and FIG. 15 show a modified embodiment of the press roller mechanism which is different from that shown in FIG. 6 and FIG. 7. This embodiment aims at making the sliding frame 19 supported by the support frame 18 slide on the support frame 18 through the medium of the rollers 58, 58. FIG. 14 and FIG. 15 show respectively a front view and a side elevational view of this modified press roller mechanism.

As described above, the present invention is designed for effecting the driving of each part automatically by a controlling mechanism on the basis of a fixed program. Although not shown in the drawings, this controlling mechanism may be an electric oil pressure system, an electric mechanical system or combination of the two systems in conventional use. The desired end plate can be manufactured automatically by the revolving of a blank held at its center between the upper and the lower support members and cooperative working of a group of OR and SR forming rollers of different shape. The end plate thus fonned is given edge preparation by usual cutting or by cutting by fusing. The present invention is characterized by: (1) its general construction, (2) a cooperative forming mechanism by the combination of the OR forming roller and the SR forming roller, (3) a mechanism to make the OR forming roller trace the locus of the end plate shape, (4) forming by means of individual working of the OR forming roller, (5) an apparatus whereby controlling mechanisms such as an electric mechanical system, an electric oil pressure system (or the combination of the two systems) are connected with each other for automatic operation, and (6) final edge preparation by usual cutting or by cutting by fusing, which is effected by the controlling mechanism.

Since the present invention involves the above-mentioned construction, it has the advantage that its construction is simple and yet strong, and also end plates of various shapes can be manufactured automatically by means of varying loci to be traced by the forming rollers.

Having thus described the nature of my invention, what I claim is:

1. An end plate forming apparatus comprising a clamping mechanism having an upper support member and a lower support member mounted on the same axis for supporting therebetween and revolving a blank to be formed into said end plate; a forming roller assembly including a forming roller mounted within the peripheral edge of said end plate, a press roller mounted without the peripheral edge of said end plate and opposite said forming roller, means operatively associated with said forming roller for moving said forming roller from the area of contact of said blank with said lower support member to the peripheral edge of said blank along a path corresponding to the desired curve of said end plate, means independent of said means for moving said forming roller and operatively associated with said press roller for moving said press roller from the area of contact of said blank with said upper support member to the peripheral edge of said blank along said path corresponding to said desired curve of said end plate; and a controlling mechanism for automatically correlating the movements of said means for moving said forming roller and said press roller in accordance with a predetermined program.

2. An apparatus as claimed in claim 1, wherein said forming roller comprises a substantially globe-shaped roller mounted on the end of a substantially vertical shaft; said means for moving said forming roller comprises a frame mounting said vertical shaft, means for displacing said frame radially of said blank, and means for displacing said frame substantially vertically; and said means for moving said press roller comprises a support frame, a sliding frame mounted on said support frame,

a press roller support frame mounted on said sliding frame,

said press roller being slantingly movable on said press roller support frame, means to displace said press roller support frame radially of said blank with respect to said sliding frame, means to displace said sliding frame vertically of said support frame, and means to displace said support frame radially of said blank.

3. An apparatus as claimed in claim 2, including two or more said forming roller assemblies.

4. An apparatus as claimed in claim 2, further comprising an auxiliary roller assembly positioned substantially opposite said forming roller assembly and comprising an auxiliary roller mounted within the peripheral edge of said blank, a receiving roller mounted without said peripheral edge of said blank and I5 opposite said auxiliary roller, means operatively associated with said auxiliary roller for displacing said auxiliary roller vertically, independent means operatively associated with said receiving roller for displacing said receiving roller radially of said blank, and independent-means operatively associated with said receiving roller for displacing said receiving roller vertically.

- 5. An apparatus as claimed in claim 4, further comprising independent means for displacing said auxiliary roller radially of said blank, and independent means for displacing said receiving roller arcuately along said path.

6. An apparatus as claimed in claim 5, wherein said controlling mechanism comprises an electrically operated oil pressure or mechanical system, and said means for moving and displacing include independent electromotive power sources operable by said system in accordance with said predetermined program. 

1. An end plate forming apparatus comprising a clamping mechanism having an upper support member and a lower support member mounted on the same axis for supporting therebetween and revolving a blank to be formed into said end plate; a forming roller assembly including a forming roller mounted within the peripheral edge of said end plate, a press roller mounted without the peripheral edge of said end plate and opposite said forming roller, means operatively associated with said forming roller for moving said forming roller from the area of contact of said blank with said lower support member to the peripheral edge of said blank along a path corresponding to the desired curve of said end plate, means independent of said means for moving said forming roller and operatively associated with said press roller for moving said press roller from the area of contact of said blank with said upper support member to the peripheral edge of said blank along said path corresponding to said desired curve of said end plate; and a controlling mechanism for automatically correlating the movements of said means for moving said forming roller and said press roller in accordance with a predetermined program.
 2. An apparatus as claimed in claim 1, wherein said forming roller comprises a substantially globe-shaped roller mounted on the end of a substantially vertical shaft; said means for moving said forming roller comprises a frame mounting said vertical shaft, means for displacing said frame radially of said blank, and means for displacing said frame substantially vertically; and said means for moving said press roller comprises a support frame, a sliding frame mounted on said support frame, a press roller support frame mounted on said sliding frame, said press roller being slantingly movable on said press roller support frame, means to displace said press roller support frame radially of said blank with respect to said sliding frame, means to displace said sliding frame vertically of said support frame, and means to displace said support frame radially of said blank.
 3. An apparatus as claimed in claim 2, including two or more said forming roller assemblies.
 4. An apparatus as claimed in claim 2, further comprising an auxiliary roller assembly positioned substantially opposite said forming roller assembly and comprising an auxiliary roller mounted within the peripheral edge of said blank, a receiving roller mounted without said peripheral edge of said blank and opposite said auxiliary roller, means operatively associated with said auxiliary roller for displacing said auxiliary roller vertically, independent means operatively associated with said receiving roller for displacing said receiving roller radially of said blank, and independent means operatively associated with said receiving roller for displacing said receiving roller vertically.
 5. An apparatus as claimed in claim 4, further comprising independent means for displacing said auxiliary roller radially of said blank, and independent means for displacing said receiving roller arcuately along said path.
 6. An apparatus as claimed in claim 5, wherein said controlling mechanism comprises an electrically operated oil pressure or mechanical system, and said means for moving and displacing include independent electromotive power sources operable by said system in accordance with said predetermined program. 